Protection devices for use in shoes or other products

ABSTRACT

A variety of devices for protecting a user&#39;s foot from injury are disclosed. In one embodiment, the device may be a metatarsal protection device, which may include a first layer of material having top and bottom surfaces, with at least one of such surfaces including a series of cones or a pattern of hexagons thereon. The metatarsal protection device may also include a second relatively rigid layer of material overlying the first layer, and the first layer may be shaped to conform to the metatarsal region of the user&#39;s foot, such that the device is configured to protect the metatarsal region against injury. Other configurations and variations of a metatarsal protection device are also disclosed, as are other uses for the principles of the invention(s) disclosed herein (e.g., protection devices for other areas of the foot, etc).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/648,839, filed on Oct. 10, 2012, which application claims the benefitof U.S. Provisional Patent Application Nos. 61/545,317 and 61/664,217,filed, respectively, on Oct. 10, 2011 and Jun. 26, 2012, the disclosuresof which are hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

Aspects of the present invention relate, in general, to protectiondevices for use in shoes, and specifically to metatarsal or otherprotection devices for shielding a user's foot from injury. Protectiondevices for use in shielding other areas of a user's foot, otherportions of the body, or in alternate applications beyond bodilyprotection are also contemplated.

Protection devices for shielding the metatarsal area of the foot frominjury are widely used in various sectors of the footwear industry.Typically, these protection devices are referred to as metatarsalguards, and may be employed as an external guard or integrated into theshoe itself (e.g., an internal guard). Common scenarios in which suchmetatarsal guards may be necessary are in construction applications, inmining, or in other like fields where the foot may be susceptible toinjury due to impact with extraneous objects (e.g., falling rocks,lumber, puncture via nails, etc.) In some cases, while theaforementioned metatarsal guard(s) may provide adequate protection frominjury, such guard(s) may restrict comfortable movement of the foot dueto the rigidity of the guard(s). Other deficiencies not noted here alsoexist.

Beyond protection of the metatarsal area of the foot, other sensitiveareas that are susceptible to injury may also require shielding. Forexample, it may be the case that the foot, in certain scenarios,requires side or heel protection instead of, or in combination with,metatarsal protection. It is not uncommon to provide such protectivedevices on the side or heel region of a shoe in order to provideshielding. Even these protective mechanisms, however, may suffer fromseveral defects, and therefore lack of comfort in use. For example, someheel (or other) protective devices are unnecessarily rigid, and therebydo not adequately absorb the shock resulting from an impact or otherinjuring event. Stated differently, since such protective devices areunduly rigid, force generated from an impact can travel through thedevice and be translated to the user, resulting in injury to the userfrom the impact. Such rigidity also decreases comfort, and sometimesresults in the protective device being overly heavy. This may also bethe case for several of the metatarsal protection devices noted above.

BRIEF SUMMARY OF THE INVENTION

A first embodiment of the present invention includes a shoe containingan upper having top and bottom layers of material or a flap having aninternal pocket, and a device for protecting the metatarsal region of auser's foot, the device being situated between the top and bottom layersof the upper or within the internal pocket. The device may comprise afirst layer of material having top and bottom surfaces and a series ofcones formed into at least one of the top and bottom surfaces, theseries of cones including individual cones of varying depth and width,and a second layer of material overlying the first layer and having arigidity that is higher than a rigidity of the first layer, the firstlayer being shaped to conform to the metatarsal region of the user'sfoot, such that the device is configured to provide protection for themetatarsal region against injurious events.

Other aspects of the first embodiment may include first and secondseries of cones being formed into the top and bottom surfaces of thefirst layer of material, respectively, the first and second seriesincluding a first set of cones having a first depth and width, and asecond set of cones having a second depth and width, the first depth andwidth being greater than the second depth and width. In some cases,individual cones within the first set may also alternate with individualcones within the second set on both the top and bottom surfaces of thefirst layer of material. It is also contemplated that the first seriesof cones may be offset with respect to the second series of cones, suchthat a terminal end of at least one cone within the first series issituated adjacent a terminal end of at least one cone within the secondseries.

In addition, in other embodiments, the series of cones formed into thedevice may be situated on the bottom surface of the first layer ofmaterial, and the top surface of the first layer of material may notinclude a series of cones.

Further aspects of the first embodiment may include a second layer thatis situated within a recess formed in the top surface of the firstlayer, the second layer including a pattern of hexagons. The pattern ofhexagons may contain a first set of outer hexagons extending from anouter surface of the second layer, such outer hexagons being defined bya perimeter, and a second set of inner hexagons situated within theperimeter and extending towards the outer surface of the second layer.The outer hexagons comprising the first set may also contain wallsdefining each hexagon, such walls being angled in one direction, and theinner hexagons comprising the second set may contain walls defining eachhexagon, such walls being angled in another direction. The inner surfaceof the second layer may also be convex in a longitudinal direction andconcave in a medial-lateral direction.

Still other aspects of the first embodiment may include a second layerthat is adhered to the top surface of the first layer, the second layerincluding inner and outer surfaces that are generally non-patterned. Thesecond layer, in some instances, may also exhibit rigidity when bent inone direction, and react with relative flexibility when bent in anotheropposing direction.

A second embodiment of the invention may include a shoe having an upperwith top and bottom layers of material or a flap having an internalpocket, and a device for protecting the metatarsal region of a user'sfoot, the device being situated between the top and bottom layers of theupper or within the internal pocket. The device, in this embodiment, maycomprise a first layer of material having top and bottom surfaces, atleast one of the top and bottom surfaces including a first pattern ofhexagons formed thereon, and a second layer of material overlying thefirst layer and having a rigidity that is greater than a rigidity of thefirst layer, the first layer being shaped to conform to the metatarsalregion of the user's foot, such that the device is configured to provideprotection for the metatarsal region against injurious events.

The first pattern of hexagons, in some aspects of the second embodiment,may include a first set of outer hexagons extending from the bottomsurface of the first layer of material, such outer hexagons beingdefined by a perimeter, and a second set of inner hexagons situatedwithin the perimeter and extending towards the bottom surface of thefirst layer. The outer hexagons comprising the first set may alsoinclude walls defining each hexagon, such walls being angled in onedirection, and the inner hexagons comprising the second set may includewalls defining each hexagon, such walls being angled in anotherdirection. The bottom surface of the first layer of material may also beconvex in a longitudinal direction and concave in a medial-lateraldirection.

In some aspects of the second embodiment, the second layer may besituated within a recess formed in the top surface of the first layer,the second layer including a second pattern of hexagons. The secondpattern of hexagons may also include a first set of outer hexagonsextending from an outer surface of the second layer, such outer hexagonsbeing defined by a perimeter, and a second set of inner hexagonssituated within the perimeter and extending towards the outer surface ofthe second layer.

Still other aspects of the second embodiment may include the secondlayer being adhered to the top surface of the first layer, the secondlayer including inner and outer surfaces that are generallynon-patterned. The second layer may also exhibit rigidity when bent inone direction, and react with relative flexibility when bent in anotheropposing direction. The first pattern of hexagons may also be formedonly on the bottom surface of the first layer of material.

In other aspects of either the first or second embodiment, the devicemay be integrally attached to the upper or the flap, or the device maybe separable from the upper or the flap.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the subject matter of the presentinvention and of the various advantages thereof can be realized byreference to the following detailed description in which reference ismade to the accompanying drawings in which:

FIG. 1 is a side view of a shoe incorporating therein an internalmetatarsal guard according to one embodiment of the present invention.

FIGS. 2A-I include top, bottom, medial, lateral, and section views of aninternal metatarsal guard according to another embodiment of the presentinvention, with FIG. 2J showing the pattern of cones formed on theinternal guard of FIGS. 2A-I.

FIGS. 3A-I include top, bottom, medial, lateral, and section views of aprotective layer usable with various embodiments of the presentinvention(s), with FIG. 3J showing the pattern of hexagons formed on theprotective layer of FIGS. 3A-I.

FIGS. 4A-I include top, bottom, medial, lateral, and section views of analternate internal metatarsal guard according to another embodiment ofthe present invention.

FIG. 5 is a side view of a shoe incorporating therein an externalmetatarsal guard according to an embodiment of the present invention.

FIGS. 6A-I include top, bottom, and section views of a rigid layerforming part of the external metatarsal guard employed in the shoe ofFIG. 5.

FIGS. 7A-H include top, bottom, medial, lateral, and section views ofone portion of an external metatarsal guard according to an embodimentof the present invention.

FIGS. 8A-H include top, bottom, medial, lateral, and section views ofone portion of an alternate external metatarsal guard according toanother embodiment of the present invention.

DETAILED DESCRIPTION

In describing aspects of the present invention(s), specific terminologywill be used for the sake of clarity. However, the invention(s) is notintended to be limited to any specific terms used herein, and it is tobe understood that each specific term includes all technicalequivalents, which operate in a similar manner to accomplish a similarpurpose.

FIG. 1 depicts a shoe 10 having an internal metatarsal guard 18according to one embodiment of the invention, such guard being situatedbetween outer 14 and inner layers 16 of an upper 12 of the shoe 10. FIG.1, at this point, serves to merely demonstrate where the variousmetatarsal guards detailed hereafter may be positioned in a shoe. Thedetailed structure of each such metatarsal guard is as follows.

Referring to FIGS. 2A-I, an internal metatarsal guard 30 according toone embodiment of the present invention is shown, in which the guard 30is adapted to provide improved flexibility while maintaining adequateprotection for the metatarsal region of a user's foot. As with guard 18discussed above, internal metatarsal guard 30 may be situated betweenouter and inner layers of an upper of a shoe (e.g., shoe 10 shown inFIG. 1) to provide protection for the foot.

In one embodiment, guard 30 may include a top surface 32 and a bottomsurface 34, each surface 32, 34 having a pattern of individual cones 36formed thereon. For example, as shown in FIGS. 2A-I, and particularlyFIG. 2J, top surface 32 of metatarsal guard 30 may have a plurality ofcones of one size 38 formed therein, and a plurality of cones of arelatively smaller size 40 extending into surface 32. Such cones 38, 40may also alternate with one another in both a longitudinal direction 42and a medial-lateral 44 direction. Likewise, a similar pattern of large38 and relatively smaller cones 40 may be situated on bottom surface 34of metatarsal guard 30, although the pattern 36 on bottom surface 34 maybe offset from the pattern 36 on top surface 32. Stated differently, asubstantially identical pattern 36 of cones 38, 40 may be situated onbottom surface 34; however, the pattern 36 on bottom surface 34 may bearranged such that a large cone 38 on surface 34 may be disposeddirectly opposite a small cone 40 on top surface 32, and vice versa.This is shown best in FIGS. 2D, 2G-H, and particularly FIG. 2J. It isalso contemplated that the pattern(s) 36 of cones 38, 40 on top 32 andbottom 34 surfaces may, instead of containing only two (2) cones ofvarying size, include three (3) or more cones each having a differentsize. An example of such a pattern of cones is described in the ExhibitsA and B.

As shown further in FIGS. 2A-I, metatarsal guard 30 may be anatomicallycontoured to conform to the shape of the foot. In particular, bottomsurface 34 of guard 30, which may be situated against the foot duringuse, may be concavely shaped in the medial-lateral direction 44, andconvexly shaped in the longitudinal direction 42. Thus, bottom surface34 of guard 30 may conform to the metatarsal region of a user's foot.

In use, metatarsal guard 30 may be positioned within a shoe, similar toshoe 10 shown in FIG. 1, and may act to protect the metatarsal area of auser's foot. Thus, metatarsal guard 30 may be utilized as an internalguard in shoe 10 to protect a user's foot from falling objects or otherimpact events, which would otherwise injure the foot.

Other configurations of guard 30 are also contemplated. For instance, inthe embodiment shown in FIGS. 2A-I, the pattern of cones 36 on topsurface 32 of guard 30 may, in some instances, form a cross-shape orregion 46. Alternatively, such guard 30 may have a top surface 32without a pattern of cones formed thereon (not shown). Thus, top surface32 of guard 30 may be relatively smooth or non-patterned. In this andother embodiments, instead of a cross-shape 46 being defined by thepattern of cones 36 on top surface 32 of guard 30, a cross-shaped recess(not shown) may be formed in guard 30.

Referring now to FIGS. 3A-I, an additional component, which is usablewith internal metatarsal guard 30 (FIGS. 2A-I), is shown. The use andconstruction of this added component is set forth below.

As shown in FIGS. 3A-I, an added protective layer 60 may have inner 62and outer 64 surfaces, and may be configured in a generally cross-typeshape. The protective layer 60 may also be anatomically contoured toconform to the metatarsal region of the foot, similar to guard 30. Thus,inner surface 62 of protective layer 60 may be convexly shaped in alongitudinal direction 66 and concavely shaped in a medial-lateraldirection 68. In a particular embodiment, inner surface 62 of protectivelayer 60 may also be adapted to abut top surface 32 of guard 30, suchthat protective layer 60 may overly guard 30. To be exact, thecross-shape of protective layer 60, as shown in FIGS. 3B and 3E, mayapproximate the cross-shape 46 formed on top surface 32 of guard 30produced via cones 38, 40. Protective layer 60 may thusly overly thecross-shape 46 on top surface 32 of guard 30 produced via cones 38, 40and provide additional impact resistant in that area.

FIGS. 3B, 3D, and particularly FIG. 3J depict, in detail, a hexagonalpattern 78 formed on outer surface 64 of protective layer 60. Thepattern 78 may include a series of outer hexagons 70 into which a seriesof respective inner hexagons 72 are formed. In other words, individualouter hexagons 70 may be situated on outer surface 64 of protectivelayer 60 and, formed or bored into each such outer hexagon 70, may be anindividual inner hexagon 72. As shown further in FIG. 3J, walls 74, 76of outer and inner hexagons 70, 72, respectively, may also be angled inopposition to one another. In particular, while walls 74 of outerhexagons 70 are situated such that the width of the respective hexagon70 increases as the walls 74 approach outer surface 64, walls 76 ofinner hexagons 72 achieve an opposite effect (e.g., the width of eachinner hexagon 72 decreases as walls 76 approach outer surface 64). Thepattern 78 of outer 70 and inner 72 hexagons may also repeat along outersurface 64, as shown in FIG. 3J (e.g., successive outer and innerhexagons 70, 72 may be situated adjacent one another on outer surface64).

The effect of the aforementioned pattern 78 of outer and inner hexagons70, 72 may be to allow for flexion of protective layer 60 in onedirection, while creating relative rigidity when protective layer 60 isbent in an opposing direction. For example, upon bending protectivelayer 60 outwards according to the downward facing arrow in FIG. 3J, thelayer 60 may behave or react with flexibility, as the walls 74 of outerhexagons 70 may simply diverge from one another. However, upon bendingprotective layer 60 inwards according to the upwards facing arrow, thelayer 60 may behave or react with rigidity, since adjacent walls 74 ofouter hexagons 70 may converge on one another. This inward bending mayalso have an effect of increasing rigidity of protective layer 60 whenimpacted with an extraneous object (e.g., falling debris, a piece oflumber, etc.) In other words, with protective layer 60 bent inwards,walls 74 of outer hexagons 70 may abut one another and be somewhatpre-compressed, and walls 76 of inner hexagons 72 may provide asupporting structure, which resists further deflection of outer hexagons70 (e.g., due to the opposing angle of walls 76). As a result, upon anextraneous object striking such protective layer 60 in the inwardly-bentorientation, the outer and inner hexagons 70, 72 may cooperate toprovide rigidity and protect a user's foot from the brunt of the impact.

In some instances, the inwardly-bent state of protective layer 60described above may be the state in which layer 60 is disposed duringuse. To be exact, since inner surface 62 of protective layer 60 may beconvexly shaped in longitudinal direction 66 and concavely shaped inmedial-lateral direction 68, protective layer 60 (or more specificallythe hexagonal pattern 78 on outer surface 64 thereof) may be bentinwards, at least partially. Thus, protective layer 60 may bepre-disposed in a somewhat rigid state due to inward bending, the natureof which is detailed above. Such rigid state, however, may be sufficientto absorb the forces generated by an impact event. With inner surface 62of protective layer 60 situated against a user's metatarsal region,protective layer 60 may therefore react with rigidity should anextraneous object strike the user's foot. Further, upon extension of theuser's foot (e.g., during normal walking), protective layer 60 may reactwith flexibility since such layer 60 would bend outwards during thismovement. The dynamic nature of the hexagonal pattern 78 of protectivelayer 60 may therefore serve to provide rigidity in instances where itis needed (e.g., upon impact with a potentially injuring object) andflexibility in others (e.g., during normal walking).

The above-described benefits of protective layer 60 may be incorporatedinto internal metatarsal guard 30 through either: (1) in one embodiment,connecting inner surface 62 of such layer 60 with top surface 32 ofguard 30 as shown and described with respect to FIGS. 2A-I; or (2)situating protective layer 60, in an overlying relationship, on aninternal metatarsal guard 30 having a smooth or non-patterned topsurface 32. In other words, with respect to embodiment (2), protectivelayer 60 may be situated on a top surface 32 of guard 30 that does nothave an alternating cone pattern 36 (e.g., such guard would have arelatively smooth or non-patterned surface). With respect to embodiment(1), protective layer 60 may be situated over the cross-shape pattern 46produced via cones 38, 40 on top surface of guard 30. Accordingly, thereare at least three (3) embodiments of internal metatarsal guard 30contemplated by the present invention, such embodiments being: (1) theinternal metatarsal guard 30 discussed with reference to FIGS. 2A-I; (2)embodiment (1) discussed above (i.e., internal metatarsal guard 30 ofFIGS. 2A-I with an overlying protective layer 60); and (3) embodiment(2) detailed above (i.e., internal metatarsal guard 30 having a smoothor non-patterned top surface 32 and a protective layer 60 overlying suchsurface).

In use, each of the aforementioned embodiments (1) to (3) of internalmetatarsal guard 30 may be situated between outer and inner layers of anupper of a shoe, such as shoe 10 of FIG. 1. Thus, much like the use ofthe internal metatarsal guard 18 discussed above, embodiments (1) to (3)of guard 30 may provide protection for the metatarsal region of a user'sfoot. However, such guard(s) 30 may also provide increased flexibilityand improved rigidity. In particular, the impact forces potentiallyexperienced during use of shoe 10 may be mitigated and absorbed viaguard(s) 30.

A further embodiment metatarsal guard 90 is shown in FIGS. 4A-I. Thisguard 90, like guard(s) 30, may be anatomically contoured to a user'sfoot, in that a bottom surface 92 of the guard 90 may be convex in alongitudinal direction 96 and concave in a medial-lateral direction 98.It is also contemplated that metatarsal guard 90 may be situated betweenouter and inner layers of an upper of a shoe to provide protectionagainst impact or other injuring events, and to absorb the forcesgenerated by such events. Indeed, metatarsal guard 90, while usable byitself in some embodiments, is one component of the internal metatarsalguard 18 shown in shoe 10 of FIG. 1.

In a particular embodiment, a pattern of hexagons 100 may be situated onbottom surface 92 of metatarsal guard 90, such pattern 100 beingidentical to the pattern 78 shown and described with reference to FIGS.3B, 3D, and particularly FIG. 3J. Thus, bottom surface 92 of guard 90may provide protection for the metatarsal region of a user's foot in asimilar way to protective layer 60. For example, it is contemplated thatthe pattern of hexagons 100 on bottom surface 92 of guard 90 may beinwardly-bent in the manner described in preceding sections, therebyadapting guard 90 to provide protection akin to protective layer 60.Stated differently, as metatarsal guard 90 may be inwardly-bent in itsnormal orientation, such guard 90 may react with relative rigidity ifimpacted with an extraneous object (e.g., the pattern of hexagons 100,and specifically the walls of each individual hexagon, may converge onone another once inwardly bent, and thereby provide a relatively rigidbut absorptive surface with which to protect a user's metatarsalregion). The rigid nature of hexagons 100 when situated in aninwardly-bent orientation is described in detail with respect toprotective layer 60.

A variant of metatarsal guard 90 may include guard 90 with a protectivelayer 60, as shown and described with reference to FIGS. 3A-J, andFIG. 1. Such layer 60 may be situated in a cross-shaped recess 102formed in guard 90, thereby positioning inner surface 62 of protectivelayer 60 against the user's foot, and outer surface 64 away from thefoot. With protective layer 60 added as a component to metatarsal guard90, such guard 90 may experience improved impact resistance and therebyprovide even further protection for a user. In one embodiment,protective layer 60 may be cemented or otherwise adhered to cross-shapedrecess 102 formed in guard 90, providing positive impact resistance inthat area. Indeed, the above-described embodiment is shown in FIG. 1 asmetatarsal guard 18 (i.e., metatarsal guard 18 comprises guard 90 with aprotective layer 60 overlying such guard 90).

FIG. 5 depicts a shoe 110 (similar to shoe 10), except that shoe 110includes an external metatarsal guard 118 according to an embodiment ofthe invention. Such guard 118, in FIG. 5, is situated between outer 114and inner 116 layers of a flap 124 connected to an upper 112 of the shoe110. As shown, flap 124 may be situated over the metatarsal area of auser's foot to provide protection therefor. Guard 118 may generallyinclude a foam or cushioning layer (described below) and an overlyingrigid layer 128, the latter being shown in detail in FIGS. 6A-I andserving to provide resistance against impact forces experienced duringnormal use of shoe 110. External guard 118 may also conform (at leastpartially) to the anatomy of a user's foot in that such guard 118 may beconvex in a longitudinal direction and concave in a medial-lateraldirection.

FIGS. 7A-H depict an embodiment of one component 202 of externalmetatarsal guard 118, such component 202 being usable with shoe 110, asshown in FIG. 5. This flexible component 202 (FIGS. 7A-H) may include atop surface 192 and a bottom surface 194, the bottom surface 194 beingrelatively straight (or in some embodiments slightly convex) in alongitudinal direction 196, and concave in a medial-lateral direction198. Further, bottom surface 194 may include a pattern of hexagons 200,such pattern 200 being identical to the patterns 78, 100 found onprotective layer 60 (FIGS. 3A-J) and internal metatarsal guard 90 (FIGS.4A-I), respectively. Thus, flexible component 202 of metatarsal guard118 may offer the same or similar protective features as found withprotective layer 60 and metatarsal guard 90.

In a particular embodiment, bottom surface 194 of flexible component 202may be situated against a user's foot, thereby resulting in inwardbending of the component 202 (or more specifically the pattern ofhexagons 200). In other words, due to the concave curvature of bottomsurface 194 of component 202 in the medial-lateral direction 198, suchcomponent 202 may be inwardly bent once situated against a user's foot.Flexible component 202 of guard 118, in this inwardly-bent state, maytherefore offer the protective qualities noted above with respect toprotective layer 60 and/or internal guard 90.

It is also contemplated that top surface 192 of flexible component 202may be adhered or cemented to an overlying rigid layer 128, such as thatshown in FIGS. 6A-I, to complete external metatarsal guard 118. Thisconstruct (external guard 118—or flexible component 202 with rigid layer128) may also be situated within a flap 124 of a shoe, such as shoe 110of FIG. 5. Indeed, flap 124 may contain a pocket for housing externalguard 118. Such guard 118 may therefore serve to protect a user's footfrom injury due to impact or other like events.

Referring now to FIGS. 8A-H, a component 232 of an alternate externalmetatarsal guard is shown, such guard also being usable within a shoesimilar to shoe 110 of FIG. 5. The flexible component 232, in thisembodiment, may include top 222 and bottom 224 surfaces that are curvedin the same or a similar manner as surfaces 192, 194 of external guard118. Thus, bottom surface 224 may be relatively straight (or convexlycurved, in one embodiment) in a longitudinal direction 226, and concavein a medial-lateral direction 228. Further, top 222 and bottom 224surfaces of component 232 may include a pattern of cones 230, suchpattern 230 being identical to or sharing attributes with the pattern 36of cones 38, 40 on internal metatarsal guard 30. Flexible component 232may therefore offer the same or similar protective qualities as internalmetatarsal guard 30, although being constructed for use in an externalmetatarsal guard.

As with external guard 118, flexible component 232 of FIGS. 8A-H, whichacts as one component of the aforementioned external guard, may becemented or otherwise adhered to rigid layer 128 of FIGS. 6A-I tocomplete the external guard. In particular, rigid layer 128 may becemented or otherwise adhered to top surface 222 of flexible component232 so as to provide increased impact resistance for the metatarsalregion of a user's foot. This construct (the external guard—or flexiblecomponent 232 with rigid layer 128) may be situated within flap 124 ofshoe 110 during use. To be exact, the external guard of theaforementioned embodiment may be situated within a pocket in flap 124.Accordingly, such external guard may be utilized in much the same manneras guard 118 for protection of a user's metatarsal region; and thus,such use is not explicitly detailed here.

In the devices depicted in the figures, particular structures are shownthat are adapted for use in a shoe, such devices serving to protect thefoot of a user of the shoe. The use of alternative structures for suchpurposes, including structures having different lengths, shapes, andconfigurations is also contemplated. As an example, other variants of aninternal metatarsal guard beyond those discussed above are contemplated.For instance, it is contemplated that, in place of protective layer 60in several embodiments, may be a non-patterned and cross-shaped rigidlayer (not shown). In other words, a rigid layer of material may beprovided, which is roughly the same shape as protective layer 60 (FIGS.3A-J), but such layer may not include a pattern of hexagons thereon.This protective layer may, in some instances, be combined with anembodiment of internal metatarsal guard 30 shown in FIGS. 2A-J. Inparticular, the aforementioned cross-shaped rigid layer may be combinedwith an internal metatarsal guard 30 having a top surface 32 that issmooth or non-patterned, such top surface 32 further including a recess(not shown) to accommodate the rigid layer. To be exact, it iscontemplated that the cross-shaped rigid layer may be disposed withinthe recess (not shown) in guard 30 to provide additional protectionagainst impact or other injuring events in that area.

As another example, the aforementioned cross-shaped rigid layer may beused with internal metatarsal guard 90 shown in FIGS. 4A-I.Specifically, such cross-shaped rigid layer may be situated withincross-shaped recess 102 in internal metatarsal guard 90 and be cementedor otherwise adhered therein. Thus, the non-patterned rigid layer, inthis embodiment, may provide increased protection for a user's footduring use.

Yet another embodiment may include substituting or replacing one ofmetatarsal guards 30, 90 with a non-patterned cushioning layer. Further,in these embodiments, the non-patterned cushioning layer may include, ina recess formed in the cushioning layer, a protective layer 60 accordingto FIGS. 3A-J. Protective layer 60, due to its cross-shape, maytherefore be situated within a cross-shaped recess (not shown) formed inthe non-patterned cushioning layer. Other configurations of internal andexternal metatarsal guards beyond those noted above are alsocontemplated.

While not explicitly detailed in preceding sections, it is alsocontemplated that the internal metatarsal guard(s) discussed above maybe integrally attached with the upper 12 of shoe 10, or such guard(s)may be separable therefrom. The same is true for the external guard(s)detailed above (e.g., such guard(s) may be integrally attached to theinternal pocket of flap 124 of shoe 110 or be separable therefrom).Thus, different internal and external metatarsal guards may besubstituted for one another within shoes 10, 110, respectively, therebyallowing a user the choice of which guard to use. Alternatively, asnoted above, the aforementioned guards may be integrally attached withshoes 10, 110, which would not allow a user to remove or substituteguards.

As another example, although the metatarsal protection devices detailedherein are predominantly convex in a longitudinal direction and concavein a medial-lateral direction, other curvatures and shapes arecontemplated. Such alternate curvatures and/or shapes may also lendthemselves to providing protection for other areas of a user's foot, orfor other areas of the body. Indeed, it is contemplated that aspects ofthe aforementioned metatarsal protection devices may be utilized inother areas of a shoe to provide protection for other areas of a user'sfoot, such as, for example, in the heel or side of the shoe. If used forthese purposes, the metatarsal protection devices disclosed herein maybe modified in shape and contour to conform to the area of the footbeing protected.

Likewise, it is contemplated that aspects of the aforementionedprotection devices may be used to protect other areas of a user's body,such as, for example, the knee, elbow, etc. In particular, protectivedevices having the different layers of material and varying patternsdiscussed above may situated within a housing and be adapted to overly asurface of the user's body, such that the applicable device couldprotect the relevant portion of the body from injury. An example of thismay be a knee or elbow guard, which utilizes at least one of theembodiments discussed above for protective purposes. In this manner, auser may be provided with several protective devices that are usable toshield varying portions of the body (e.g., including, but not limitedto, the foot, knee, elbow, etc.)

Aspects of the present invention(s) may also be utilized in other areasbeyond footwear protection. For instance, a protective device for a cellphone, computer, or other electronic device may be manufactured usingseveral of the concepts detailed above. To be exact, an electronicdevice cover may be constructed using the above-noted technology, suchcover including an inner surface or pocket for housing the device, andan outer surface for protecting the device from damage. In someembodiments, the electronic device cover may be composed of a foam orother material providing cushioning characteristics, and such foam orother material may include a pattern of cones or hexagons ashereinbefore described with reference to the figures.

For instance, in one embodiment, an inner surface of the electronicdevice cover may be relatively smooth, and an outer surface of the covermay have a pattern of cones or hexagons formed thereon to provideprotection for the electronic device (e.g., from damage due to impactwith another object, etc.) Alternatively, both the interior and exteriorsurfaces of the electronic device cover may include a pattern of conesor hexagons similar to that set forth above. In still anotherembodiment, it is contemplated that such pattern of cones or hexagonsmay only be formed on the interior of the cover, while the exterior maybe relatively smooth. Thus, a number of combinations related to anelectronic device cover are possible, the end result being a cover thatprotects the applicable device from damage via the various qualities ofthe cone and/or hexagon pattern formed on the cover. Such device cover,in some embodiments, may also conform generally to the shape of thedevice being protected (e.g., computer, iPod, cell phone, iPad, tablet,etc.)

Although aspects of the invention(s) herein have been described withreference to particular embodiments, it is to be understood that theseembodiments are merely illustrative of aspects of the presentinvention(s). It is therefore to be understood that numerousmodifications may be made to the illustrative embodiments and that otherarrangements may be devised without departing from the spirit and scopeof the present invention(s) as defined by the appended claims.

It will also be appreciated that the various dependent claims and thefeatures set forth therein can be combined in different ways thanpresented in the initial claims. It will also be appreciated that thefeatures described in connection with individual embodiments may beshared with others of the described embodiments.

The invention claimed is:
 1. An article of apparel, comprising: a housing sized to retain a protection device, the housing being arranged adjacent a portion of a body of a user; and a protection device positioned within the housing, the protection device comprising: a first layer of material having first and second opposing surfaces and a series of frustum-shaped recesses formed along at least one of the first and second surfaces, wherein the series of frustum-shaped recesses includes a first frustum-shaped recess with a first depth and width and a second frustum-shaped recess with a second, different depth and width; and a second layer of material attached to the first layer and having a rigidity that is higher than a rigidity of the first layer, the first layer being shaped to conform to the portion of the user's body, such that the protection device is arranged to provide protection for the portion of the user's body against injurious events.
 2. An article of apparel according to claim 1, wherein a first set of the first and second frustum-shaped recesses alternate along a lateral axis of the protection device, and a second set of the first and second frustum-shaped recesses alternate along a longitudinal axis of the protection device.
 3. An article of apparel according to claim 1, wherein the first frustum-shaped recess is formed along the first surface of the first layer of material, and the second frustum-shaped recess is formed along the second surface of the first layer of material, the second frustum-shaped recess being inverted with respect to the first frustum-shaped recess.
 4. An article of apparel according to claim 3, wherein the first and second frustum-shaped recesses are defined by a generally frustoconical region terminating in a circular end, and the circular end of the first frustum-shaped recess is adjacent the circular end of the second frustum-shaped recess.
 5. An article of apparel according to claim 1, wherein each of the frustum-shaped recesses has a substantially continuous internal wall surface defining the frustum shape thereof.
 6. An article of apparel according to claim 1, wherein the series of frustum-shaped recesses includes a pattern of hexagonal-shaped recesses.
 7. An article of apparel according to claim 6, wherein each hexagonal-shaped recess comprises an inner hexagonal-shaped recess that is surrounded by an outer hexagon, the outer hexagon including walls extending alongside the inner hexagonal-shaped recess.
 8. An article of apparel according to claim 1, wherein the second layer of material has first and second opposing surfaces and a series of frustum-shaped recesses are formed along at least one of the first and second surfaces.
 9. An article of apparel according to claim 1, wherein the protection device is selected from the group consisting of a metatarsal guard for a shoe, a foot guard for protection of a portion of the user's foot, a knee guard, and an elbow guard.
 10. An article of apparel according to claim 1, wherein the frustum-shaped recesses have a shape selected from the group consisting of a frustum of a cone and a hexagonal prism.
 11. An article of apparel, comprising: a housing sized to retain a protection device, the housing being arranged adjacent a portion of a body of a user; and a protection device positioned within the housing, the protection device comprising first and second layers of material, the second layer of material being attached to the first layer of material and having a rigidity that is higher than a rigidity of the first layer, wherein the second layer of material includes first and second opposing surfaces, and a series of frustum-shaped recesses is formed along at least one of the first and second surfaces, the first layer of material being shaped to conform to a portion of a user's body to provide protection against injurious events.
 12. An article of apparel according to claim 11, wherein each of the frustum-shaped recesses has a substantially continuous internal wall surface defining the frustum shape thereof.
 13. An article of apparel according to claim 11, wherein the frustum-shaped recesses have a shape selected from the group consisting of a frustum of a cone and a hexagonal prism.
 14. An article of apparel according to claim 11, wherein the first layer of material includes first and second opposing surfaces and a series of frustum-shaped recesses is formed along at least one of the first and second surfaces.
 15. An article of apparel according to claim 14, wherein at least one of the series of frustum-shaped recesses formed along the first layer of material and the series of frustum-shaped recesses formed along the second layer of material includes a series of recesses in which each of the recesses is shaped as a hexagonal prism.
 16. An article of apparel according to claim 11, wherein the second layer of material exhibits rigidity when bent in a first direction, and reacts with relative flexibility when bent in a second, opposing direction.
 17. An article of apparel according to claim 11, wherein the frustum-shaped recesses are formed along the second surface of the second layer of material.
 18. An article of apparel according to claim 11, wherein the protection device is selected from the group consisting of a metatarsal guard for a shoe, a foot guard for protection of a portion of the user's foot, a knee guard, and an elbow guard.
 19. An article of apparel, comprising: a protection device comprising first and second layers of material, the second layer of material being attached to the first layer of material and having a rigidity that is higher than a rigidity of the first layer, wherein the first and second layers of material each includes first and second opposing surfaces, respectively, and a series of frustum-shaped recesses is formed along at least one of the first and second surfaces of either the first or the second layer of material, wherein the series of frustum-shaped recesses includes a first frustum-shaped recess with a first depth and width and a second frustum-shaped recess with a second, different depth and width, the first layer of material being shaped to conform to a portion of a user's body to provide protection against injurious events.
 20. An article of apparel according to claim 19, further comprising a housing sized to retain the protection device, the housing being arranged adjacent a portion of a body of the user, wherein the protection device is positioned within the housing.
 21. An article of apparel according to claim 19, wherein the protection device is selected from the group consisting of a metatarsal guard for a shoe, a foot guard for protection of a portion of the user's foot, a knee guard, and an elbow guard.
 22. An article of apparel according to claim 19, wherein each of the frustum-shaped recesses has a substantially continuous internal wall surface defining the frustum shape thereof.
 23. An article of apparel according to claim 19, wherein each of the first and second layers of material includes a series of frustum-shaped recesses formed along at least one of the first and second opposing surfaces thereof. 